Roof expansion joint covers



Jan.- 14, 1969 c. P. BALZER ET AL 3,421,267

ROOF EXPANSION JOINT COVERS Filed Nov. 5, 1966 Sheet of 3 INVENTORS. CLAUDE R BALZER EDUARD H. CORHAN "a BY ALMER A. REM-"F AM/546x ATTORNEYS Jan. 14; 1969 c. P. BALZER ET Ag. 3,421,267

ROOF EXPANSION JOINT COVERS-- Filed Nov. 3, 1966 Sheet 2 of CLAUDE R BALZER EDWARD MCORMAN BY A'LMER A. REIFF wad 566K ATTORNEYS Jan. 14, 1969 C. P. BALZER ET AL ROOF EXPANSION JOINT COVERS Sheet J of Filed Nov. 3, 1966 I" \"-F?\"TUR 5 CLAUDE BALZER EDWARD r1. CORHAM w BY ALMER-A. REIFF gr-ronncvs United States Patent 3,421,267 ROOF EXPANSION JOINT COVERS Claude P. Balzer, Edward M. Corman, and Almer A.

Reiif, Wichita, Kans., assignors to Central Specialties Co., a corporation of Illinois Filed Nov. 3, 1966, Ser. No. 591,797

US. Cl. 52-58 Int. Cl. E04d 13/14; E041) 1/62; E041? 17/00 2 Claims ABSTRACT OF THE DISCLOSURE This invention relates to building construction and more particularly, to expansion joint deck covers.

Expansion joints in roof structures are commonly provided to allow for relative movement between structures caused by temperature variations or other forces. Such expansion joints are usually in the form of an elongated slot or opening defined by horizontally spaced apart structural edge members or an edge member spaced hori zontally from a vertical end wall or riser. Expansion joint covers have been used to prevent the elements from entering into the slot or opening, the prime requisite of such covers being the ability to expand and contract across the joint without permitting leakage or entry of the elements from the outside to the inside of the building.

Existing joint covers however, have presented one or more undesirable features, for example, a tendency to admit internally formed condensation into the joint and trap condensation in enclosed cover portions, excessive resistance against relative movement between opposed cover parts and between cover parts and the structural edge members causing loosening with respect to the structural edge members, excessive flexing, rubbing or exposure of parts causing short seal life, poor seal joints between flexible and rigid parts, lack of resistance against shocks or strains, and inability to permit both vertical as well as horizontal relative movement between the joint forming members.

The principal objects of the present invention are: to provide an expansion joint cover assembly wherein enclosed condensate is quickly drained to the exterior; to provide such a joint cover having gutters for catching condensate forming on interior cover walls whereby the condensate is not admitted into the building; to provide such an expansion joint cover having a highly flexible seal joined to side members through a tortuous seal path producing an improved seal joint therebetween; to provide such a cover assembly wherein great freedom is permitted for the cover sections to move horizontally relative to each other as well as to expand and contract longitudinally on the structural edge members; to provide cover structure having freedom to permit both horizontal and vertical relative movement; to provide such cover structure which resists cracking or damage due to shocks or strain; and to provide such a deck cover assembly which is relatively simple and inexpensive in construction, presents little resistance to movement with the expansion joint while maintaining a tight, effective seal, and is well suited for its intended purpose.

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Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings wherein are set forth by way of illustration and example certain embodiments of this invention.

FIG. 1 is a fragmentary cross-sectional perspective view showing an expansion joint cover assembly embodying this invention mounted on horizontally spaced apart structural members forming an expansion joint.

FIG. 2 is a fragmentary cross-sectional perspective view of a modified expansion joint cover assembly embodying this invention adapted for use between a structural roof member and a vertical wall or riser.

FIG. 3 is a cross-sectional end elevation through a further modified joint cover structure adapted to permit both vertical and horizontal relative movement between structural members.

FIG. 4 is a cross-sectional end elevation through a still further modified expansion joint cover assembly similar to that of FIG. 2 but adapted to permit both vertical and horizontal relative movement.

Referring to the drawings in more detail:

The reference numeral 1 (FIG. 1) generally indicates an expansion joint deck cover assembly embodying this invention. The assembly 1 is shown mounted on roof structural members 2 and 3 disposed in spaced relationship and defining an elongated slot or joint 4 therebetween. The assembly 1 comprises a pair of elongated relatively rigid sections 5 and 6 for example, of extruded aliminum, each being mirror images of the other. The sections 5 and 6 respectively have upper portions 7 and 8, intermediate portions 9 and 10 and foot portions 11 and 12.

The foot portions 11 and 12 extend respectively horizontally away from the joint 4 at 13 and 14 and have longitudinally spaced apart screw receiving longitudinally oval slots 15 therethrough for mounting the foot portions along the structural members 2 and 3. The foot portions are secured in position on the structural members by means of suitable screws 16. The oval slots 15 permit longitudinal movement to relieve any tendency to bind due to variations in temperature expansion characteristics between the foot portions and the structural members. With the foot portions 11 and 12 so mounted, the intermediate portions 9 and 10 extend upwardly and inwardly toward each other above the joint 4.

The upper portions 7 and 8 each have spaced apart upper and lower longitudinally contiuous outwardly extending bosses 17 and 18 thereon respectively forming an outwardly opening V-shaped groove 19 therebetween. The respective bosses 17 and 18 have longitudinally spaced apart threaded blind bores 20 and 21 extending thereinto above each other. The upper portions 7 and 8 also each have outwardly projecting adjacent lips 22 and 23 spaced above the bosses 17 forming tortuous sealing paths 24- for engaging an elongated flexible seal 25 now described.

The seal 25 is preferably of flexible vinyl having an elongated central dome or crown 26 bulging upwardly and extending above and across the upper portions 7 and 8. The seal 25 is shaped in a manner forming downwardly sloping legs 27 which project oppositely outwardly to an edge 28 where they turn respectively inwardly into engagement with the upper lip 23. The legs of the seal 25 then project horizontally outwardly, downwardly and then inwardly and upwardly so as to cover the exposed surfaces of the lips 22. Thus, the legs of the seal 25 closely follow the tortuous path 24 to produce a highly effective seal between the upper portions 7 and the seal 25. This prevents movement of air or moisture thereacross although great freedom is provided for the sections 5 and 6 to move toward and away from each other with horizontal relative movement of the structural members 2 and 3. During such movement the spacing variation is taken up by varying the height and curvature of the crown 26 and the flexible movement of the seal legs 27.

First and second elongated extruded vertical side walls 29 and 30 (FIG. 1) are preferably formed of the same material and in the same manner as the sections and 6. The side walls 29 and 30 each have bores 31 and 32 therethrough and spaced therealong for receiving screws 33 and 34 which threadedly engage respective boss bores 20 and 21 for rigidly mounting the respective side walls on the upper portions 7 and 8 in parallel spaced apart relation.

The side walls 29 and 30 each have a leg 35 and 36 depending vertically below the respective lower bosses 18 and terminating in a protrusion 37 directed toward but spaced from the respective section intermediate portions 9 and 10. The first side wall 29 has an upper portion 38 projecting above the seal dome 26. A horizontal wall 39 is integral with and supported by the first side wall upper portion 38 and extends across the assembly covering the seal dome 26. The horizontal wall 39 extends beyond the second side wall 30 and has a depending lip 40 positioned outwardly of the second wall 30. The horizontal wall 39 has a lower surface 41 extending at right angles or normal to the second side wall 30.

The second side wall 30 has an upper portion 42 projecting above the seal dome 26, in the manner of the upper portion 38, and terminates in an upwardly open gasket receiving groove 42' extending therealong. A suitable nonmetallic gasket 43 is slidably received in the gasket groove 42 and slidably contacts the lower surface 41 to provide a moving seal between the wall 30 and the wall 39 to substantially enclose a volume or space 44 directly above the seal 25. A plurality of weep holes 45 extend through the respective side walls 29 and 30 and are spaced longitudinally therealong adjacent the seal legs 27 where the legs are engaged in sealing contact with the inside surfaces of the side walls 29 and 30. Due to the slope of the seal dome 26 and seal legs 27, condensate water forming within the volume 44 drains down to the lowest points 46 within the volume 44 which is the junction between the seal legs 27 and the inside surfaces of the side walls 29 and 30. Since this is the point where the weep holes 45 are located, the condensate water drains through the weep holes to the exterior where it evaporates.

The foot portions 11 and 12 extend horizontally inwardly beneath the junction with the intermediate portions 9 and and terminate in inner edges 47 and 48 respectively located adjacent the sides 49 and 50 of the joint 4. The foot portion inner edges 47 and 48 each have an upwardly extending lip 51 and 52 respectively integral therewith forming gutters 53 and 54 with the foot portions and inner lower part of the intermediate portions 9 and 10. The gutters 53 and 54 catch downwardly running condensation formed on the inside surfaces 55 and 56 of the intermediate portions and the inside surface 57 of the seal 25 preventing the moisture from falling into the joint 4.

The sections 5 and 6 are supplied, for example, in 10-foot lengths and when mounted on the structural members 2 and 3, approximately a half-inch is recommended between adjacent ends 58 and 59 to permit longitudinal expansion in response to temperature changes in the assemblies. The seals 25 are normally supplied in rolls of greater than lO-foot lengths and normally extend across the longitudinal expansion space provided between adjacent sections, FIG. 1. To prevent theelements from entering the transverse joint space, a joint'cover generally indicated 60 is provided. The cover 60 comprises a sheet metal lower panel 61 which overlaps the opposite ends 58 and 59 and covers the outside surface 62 of each of the intermediate portions 9 and 10 adjacent the joint. The lower panels 61 extend rom an upper position 63 (FIG. 3)

within a groove 64 formed adjacent the lower bosses 18 to a lower position 65 which projects over and beyond the outer foot portions at 13. The lower panels 61 are suitably secured in position by screws 66 extending therethrough and into the respective structural members 2 and 3.

The joint covers 60 include a first sheet metal upper panel 67 (FIG. 3) which is longitudinally coincident with the lower panels 61 and covers the exterior of the first side walls 29 adjacent the transverse joint. The first upper panel 67 turns and covers the horizontal wall 39 and further the depending lips 40 and the exposed edges 68 of the first side wall depending lip 40. A second sheet metal upper panel 69 (FIG. 1) is also longitudinally coincident with the lower panels 61 and covers the exterior of the second side walls 30 adjacent the transverse joint. The panel 69 is turned outwardly at 41' loosely contacting the horizontal wall lower surface 41 and inwardly over the lower edge of the second side wall depending leg 35.

The upper panels 67 and 69 have longitudinally directed oval slots 70 therethrough in positions corresponding to the threaded boss bores 20 and 21 adjacent the opposed ends 58 and 59 for receiving screws therethrough in mounting the respective panels but permitting the longitudinal movement of the ends 58 and 59 toward and away from each other without causing binding or buckling of the metal.

Stress relieving channels or grooves 71 are provided in the structure at corners and other locations of high stress to permit deflection of the assembly under shock or strain without producing stress concentrations which may result in cracking. The grooves 71 are also located at the juncture of the groove 19 between the respective bosses 17 and 18 for the same purpose.

The respective side walls 29 and 30 have inwardly projecting teeth 72 forming tapering outside surfaces which mate with the inwardly directing surfaces of the groove 19 to accurately position the side walls with respect to the remaining cover structure. The slight deflection of the sections 5 and 6 at the upper portions 7 and 8 due to the receipt of the teeth 72 is relieved by the groove 71 located at the juncture between the bosses 17 and 18.

The above described expansion joint cover assembly thus provides an accurate, rugged structure which freely permits the horizontal expansion and contraction of the longitudinal joint 4 without permitting leakage between the interior and exterior of the building. Longitudinal expansion and contraction of the joint cover structure itself is freely permitted for maintaining minimum stress therein. Roof covering material 73 adjacent the joint 4 is easily received between the depending legs 35 and 36 and the respective intermediate portions 9 and 10'. A seal is produced with the material 73 upon tightening the screws 33 and 34. The flexible seal 25 is protected against outside exposure by means of the enclosing structure formed by the side walls. Condensate forming in the enclosed volume 44 is permitted to drain through the weep holes 45 in order to further maintain a desirable environment for the seal 25 which promotes long life. The accidental introduction of water between the seal 25 and the sections 5 and 6 is effectively resisted by the tortuous seal path 24 provided therebetween. Condensation or accidental water produced within the cover apparatus below the seal 25 is caught in the gutters 53 and 54 rather than introduced into the building structure.

Referring to FIG 2, an embodiment of this invention is shown which is adapted for use at a joint 74 located between a vertical wall or riser 75 and a structural roof member 76. This modified assembly is indicated by the reference numeral 77 and comprises structure identical to approximately the right half of the assembly -1 described above in connection with FIG. 1. However, the structure forming the juncture with the wall 75 includes an extruded section 78 which is integral with the horizontal wall 79 and has a plurality of projecting lips 80 forming a tortuous seal path with corresponding portions 81 on the modified seal 82. The section 78 has a groove 83 opening toward the wall 75 and receiving a gasket 84 which projects therefrom against the wall 75 and produces a seal therewith. A lip 85 extends upwardly from the section 78 forming a trough 86 for receiving suitable calking compound 87 to improve the seal at the juncture with the wall 75. A suitable anchor screw 88 extends through oval slots 89 spaced along the section 78 for maintaining the section tightly against the wall 75 but permitting longitudinal expansion and contraction of the structure as described above. A sheet metal upper panel 90 is suitably modified to cover the exterior surfaces of the section 78 at the junction between sections including the upwardly extending lip 85.

Referring to FIG. 3, the deck cover assembly shown is identical with that described in connection with FIG. 1 with the exception that the side wall 30 is replaced with a compound side wall 91 permitting freedom of relative movement both vertically and horizontally between the structural members 2 and 3. Such double freedom of movement is required, for example, in areas where seismic disturbances can be expected. The side wall 91 comprises a lower portion 92 identical to the lower portion of the side wall 30 (FIG. 1) but having an upper portion 93 adapted to receive thereagainst the lower anchor flange 94 of a thin, flexible spring wall 95. The lower anchor flange 94 is rigidly secured in position by an elongated holding bar 96 through which spaced apart screws 97 extend which are threadedly engaged with the wall upper portion 93. Weep holes 97' extend through the side wall 91 and function as the weep holes 45 noted above.

The spring wall 95 preferably is of resilient metal and extends along the entire length of the deck cover assembly, that is, coextensive with the sections 5 and 6. The spring Wall 95 includes a lower wall portion 98 normally sloping downwardly and outwardly of the assembly and integrally joining the lower anchor flange 94 in a curved joint 99. A curved joint 100 integrally connects the upper end of the wall portion 98 to the inner end of an upper wall portion 101 forming part of the spring wall 95. The upper wall portion 101 normally extends outwardly generally parallel to horizontal wall 39 and terminates in an outer end 102 which is turned upon itself forming a channel 103. The outer end 102 is flexibly secured to the lower surface 41 at the junction with the depending lip 40 by means of a seal connector 104. The seal connector 104 is preferably of vinyl and spirals about the end 102, filling the channel 103, to form an effective seal therebetween. A portion 105 of the seal connector outer surface is ridged so as to receive a suitable adhesive 106 for securing the seal connector, and thereby the end 102, to the lower horizontal wall 39. A panel 107 which functions like the panel 69 described above covers adjacent ends of the side wall 91, including the spring wall 95, at the longitudinal break between assembly sections' The panel 107, however, is flexible at least where it covers the spring wall 95 and is resiliently sprung thereagainst to maintain contact therewith during vertical and/ or horizontal movement between the structural members 2 and 3.

The structure shown in FIG. 4 is identical with that shown in FIG. 2 but modified in the same manner and for the same purpose as the structure of FIG. 3 over that of FIG. 1.

It is to be understood that although certain forms of this invention have been illustrated and described, it is not to be limited thereto except insofar as such limitations are included in the following claims.

What we claim and desire to secure by Letters Patent is:

1. An expansion joint cover assembly for roof members disposed in spaced relationship and defining an elongated joint therebetween, said assembly comprising:

(a) an elongated relatively rigid section, said section having an upper portion, an intermediate portion and a foot portion, said foot portion extending respectively away from said joint and having screw receiving openings therethrough for mounting said foot portion along one of said roof members,

(b) said upper portion having projecting lip means,

(0) an elongated flexible seal having an upwardly directed crown portion extending across said joint and terminating on one side thereof in leg means engaged with said lip means and forming a sealing path therewith,

(d) upper and lower longitudinally extending bosses projecting outwardly from said upper portion and having adjacent walls forming a V groove therebetween, and

(e) cover means for said seal and including an upwardly extending side wall mounted on said bosses, said side wall having inwardly directed projections in said groove and engaging said adjacent walls for positioning said side wall with respect to said section.

2. The cover assembly as set forth in claim 1 including:

(a) a stress relieving channel at the base of said V groove and extending therealong.

References Cited UNITED STATES PATENTS Re. 25,733 2/1965 Patry et al 52403 X 967,626 8/ 1910 Ferres 52-303 1,090,158 3/1914 Le Baron 52396 1,411,882 4/1922 Eberl 52463 2,160,758 5/1939 Schurman 52573 X 2,801,601 8/1957 Riedel 5211 3,176,806 4/1965 Ferrell 52463 X 3,296,762 1/1967 Thorn 52395 FOREIGN PATENTS 202,340 7/ 1956 Australia.

ALFRED C. PERHAM, Primary Examiner.

US. Cl. X.R. 

